Process Engineer I

JOB PURPOSE:

To manage and optimize the entire aluminium recycling process — from raw material preparation in the sorting line, through melting, refining, casting, homogenisation, and inspection — ensuring safe, efficient, and cost-effective operations. The role integrates process control, metallurgical analysis, and process efficiency, while also overseeing chemical analysis via spectrometry and maintaining raw material quality assurance.

Ensure products are produced in best quality, on time as per agreed customer requirements and meeting following international standards:

ISO 9001: 2008

ISO/TS 16949: 2009

ISO 14001:2004

ISO 45001 & ISO 45003

ISO/IEC 17025

KEY ACCOUNTABILITIES:

EHS & Compliance

• Ensure strict adherence to EHS policies, procedures, and risk assessments across all plant areas.
• Conduct safety walkabouts, toolbox talks, and actively contribute to a strong safety culture.
• Support compliance with quality and environmental standards.

Sorting Line & Raw Material Quality

• Oversee the sorting line equipment (pre-shredder, hammer mill, magnetic separator, trommel, eddy current separator, x-ray machine).
• Ensure raw material streams are correctly identified, sorted, and blended for maximum productivity and alloy accuracy.
• Inspect and evaluate alloying elements, scrap, consumables, and trial materials.
• Manage non-conformances, liaising with suppliers and supply chain on quarantines and corrective actions.
• Develop traceability and KYC practices for incoming scrap.

Melting, Holding & Casting Operations

• Monitor furnace operations (twin chamber furnace, holding furnaces, SNIF degassers) and ensure efficient and productive usage.
• Verify process compliance in casting of T-bars and billets of various diameters using Wagstaff

casting technology.

• Supervise billet and T-bar sawing, billet handling, cooling, and homogenization processes.
• Trouble shoot, monitor and optimize VDC  casting process parameters
• Manage automated billet surface inspection and volumetric inspection systems.

Metallurgy & Chemical Analysis

• Manage and operate spectrometer for melt and product chemistry analysis; validate alloy specifications.
• Ensure products meet metallurgical quality requirements.
• Conduct metallographic and metal cleanliness evaluations (PoDFA, SEM/EDX, image analysis).
• Investigate customer complaints and product/process non-conformances, prepare technical reports, and recommend corrective actions.
• Benchmark products against competitors and ensure compliance with customer quality requirements.

Process Efficiency & Optimization

• Plan and lead process optimization initiatives, throughput studies, and equipment utilization improvements.
• Recommend and implement improvements to casting management systems to enhance productivity and reduce costs.
• Research and introduce feasible new technologies and practices for recycling and casting.
• Collect and analyze operational and quality data to recommend continuous improvement actions.

Resource & People Development

• Provide technical guidance and training to operators and technicians in process monitoring, metallography, chemical analysis, and spectrometry.
•  Support graduate trainees and UAE nationals in skills development programs.
•  Contribute to cross-functional collaboration with operations, maintenance, supply chain, and quality departments.

AUTHORITY/ DECISION MAKING:

• Authority to accept/reject raw materials and consumables based on quality checks.
• Authority to release or hold cast products based on metallurgical and spectrometric analysis.
• Authority to recommend process adjustments and implement corrective actions to meet safety, quality, and productivity objectives.

QUALIFICATIONS & SKILLS:

Minimum Qualifications:

• Bachelor’s Degree in Metallurgy, Materials Science, Chemical, or Mechanical Engineering (or equivalent)
• 3–5 years’ experience in aluminum casthouse, smelting, or recycling operations.
• Hands-on experience with spectrometers, metallography, or casting operations preferred.
• Skills:
• Strong knowledge of aluminium metallurgy, alloy specifications, and recycling processes.
• Competence in metallography techniques, image analysis, and metal cleanliness assessment.
• Technical and analytical skills, including SPC and data-driven problem-solving.
• Knowledge of Vertical Direct Chill casting process and associated defect mechanisms.
• Knowledge of process optimization, lean principles, and equipment utilization.
• Effective communication, leadership, and report writing skills.